Modifying patterned features using a directional etch
View Patent ↗Disclosed herein are approaches for modifying patterned features using a directional etch. In one approach, a method may include providing a stack of layers of a semiconductor device, forming an opening through the stack of layers, the opening defined by a first sidewall and a second sidewall, and delivering ions into the first sidewall in a reactive ion etching process. The ions maybe delivered at a first non-zero angle relative to a perpendicular extending from the substrate, wherein the reactive ion etching process removes a first portion of the stack of layers from just a lower section of the first sidewall.
1. A method, comprising:
providing a stack of layers of a semiconductor device;
forming an opening through the stack of layers, the opening defined by a first sidewall and a second sidewall; and
delivering ions into the first sidewall in a reactive ion etching process, wherein the ions are delivered at a first non-zero angle relative to a perpendicular extending from the stack of layers, wherein the reactive ion etching process removes a first portion of the stack of layers from just a lower section of the first sidewall, and wherein a plane defined by the lower section of the first sidewall is oriented at the first non-zero angle after the lower portion is removed.
2. The method of claim 1 , wherein the reactive ion etching process does not remove a second portion of the stack of layers from an upper section of the first sidewall.
3. The method of claim 2 , further comprising delivering ions into the second sidewall in a second reactive ion etching process, wherein the ions are delivered at a second non-zero angle relative to the perpendicular extending from the stack of layers, and wherein the second reactive ion etching process removes a first portion of the stack of layers from a lower section of the second sidewall without removing a second portion of the stack of layers from an upper section of the second sidewall.
4. The method of claim 3 , wherein providing the stack of layers comprises:
forming a first layer over a base layer; and
forming a second layer over the first layer, wherein the first layer is a first material, and wherein the second layer is a second material different than the first material.
5. The method of claim 4 , wherein providing the stack of layers further comprises:
forming a third layer over the second layer; and
forming a fourth layer over the third layer, wherein the third layer is a third material, and wherein the fourth layer is a fourth material different than the third material.
6. The method of claim 5 , further comprising delivering ions into the first sidewall in a third reactive ion etching process, wherein the ions are delivered at a third non-zero angle relative to the perpendicular extending from the stack of layers, and wherein the third reactive ion etching process removes a lower portion of the third layer along the first sidewall without removing an upper portion of the third layer along the first sidewall.
7. The method of claim 6 , further comprising delivering ions into the second sidewall in a fourth reactive ion etching process, wherein the ions are delivered at a fourth non-zero angle relative to the perpendicular extending from the stack of layers, and wherein the fourth reactive ion etching process removes a lower portion of the third layer along the second sidewall without removing an upper portion of the third layer along the second sidewall.
8. The method of claim 6 , wherein the first non-zero angle is the same as the third non-zero angle.
9. A method for patterning opening sidewalls, the method comprising:
providing a stack of layers of a semiconductor device, the stack of layers comprising:
a first layer formed over a base layer;
a second layer formed over the first layer; and
a third layer formed over the second layer;
forming an opening through the stack of layers; and
directing ions into a sidewall of the first layer in a first reactive ion etch process, wherein the ions are delivered through the opening at a first non-zero angle relative to a perpendicular extending from the stack of layers, wherein the first reactive ion etch process removes a lower portion of the sidewall of the first layer, and wherein a plane defined by the sidewall of the first layer is oriented at the first non-zero angle after the lower portion of the sidewall of the first layer is removed.
10. The method of claim 9 , further comprising directing ions into a sidewall of the second and third layers during the first reactive ion etch process, wherein the first layer is a first material, wherein the second layer is a second material-different than the first material, and wherein the third layer is a third material different than the second material.
11. The method of claim 10 , wherein a first etch rate of the first layer is different than a second etch rate of the second material and different than a third etch rate of the third material, and wherein a difference between the first etch rate and the third etch rate causes a plane defined by the sidewall of the third layer to be oriented at a different angle than the plane defined by the sidewall of the first layer.
12. The method of claim 10 , wherein a first etch rate of the first layer is the same as a third etch rate of the third material, and wherein a plane defined by the sidewall of the third layer is oriented at a same angle as the plane defined by the sidewall of the first layer.
13. The method of claim 9 , further comprising directing ions into a sidewall of the third layer in a second reactive ion etch process, wherein the ions are delivered through the opening at a second non-zero angle relative to the perpendicular extending from the stack of layers, wherein the second reactive ion etch process removes just a lower portion of the sidewall of the third layer.
14. The method of claim 13 , wherein the second reactive ion etch causes a plane defined by the sidewall of the third layer to be oriented at the second non-zero angle after the lower portion of the sidewall of the third layer is removed, and wherein the first non-zero angle is different than the second non-zero angle.
15. The method of claim 13 , wherein the second reactive ion etch process impacts the third layer without impacting the first layer.
16. A method, comprising:
providing a stack of layers of a semiconductor device, the stack of layers comprising:
a first layer formed over a base layer;
a second layer formed over the first layer; and
a third layer formed over the second layer;
forming an opening through the stack of layers; and
directing ions into a sidewall of the first layer in a first reactive ion etch process, wherein the ions are delivered through the opening at a first non-zero angle relative to a perpendicular extending from the substrate, wherein the first reactive ion etch process removes a lower portion of the sidewall of the first layer without removing an upper portion of the sidewall of the first layer, and wherein a plane defined by the sidewall of the first layer is oriented at the first non-zero angle after the lower portion of the sidewall of the first layer is removed.
17. The method of claim 16 , further comprising directing ions into a sidewall of the second and third layers during the first reactive ion etch process, wherein the first layer is a first material, wherein the second layer is a second material different than the first material, and wherein the third layer is a third material-different than the second material.
18. The method of claim 17 , wherein a first etch rate of the first layer is different than a second etch rate of the second material and different than a third etch rate of the third material, and wherein a difference between the first etch rate and the third etch rate causes a plane defined by the sidewall of the third layer to be oriented at a different angle than the plane defined by the sidewall of the first layer.
19. The method of claim 17 , wherein a first etch rate of the first layer is the same as a third etch rate of the third material, and wherein a plane defined by the sidewall of the third layer is oriented at a same angle as the plane defined by the sidewall of the first layer.
20. The method of claim 16 , further comprising directing ions into a sidewall of the third layer in a second reactive ion etch process, wherein the ions are delivered through the opening at a second non-zero angle relative to the perpendicular extending from the substrate, wherein the second reactive ion etch process removes just a lower portion of the sidewall of the third layer.